I am looking to cost effectively upgrade old analog controls to PLC+HMI hardware for SCR controlled rectifiers. There are 100+ units in the field, usually outdoors in NEMA 4X enclosures.
The operation is as follows:
Analog Inputs: 1-4 x References (-5 to 5V, high input impedence), 1 x shunt to monitor current (0-150mV), 1 x to monitor output voltageDC V (0-12 V can be stepped down if required), 2 x RTD inputs for enclosure/SCR temperature.
Analog Output: PID controlled Process output to SCR trigger module (0-5 or 10 V or 4-20 mA).
Relay/Digital Outputs: to drive fans, status LED, etc.
PID control using reference AI as feedback to drive AO, 0-100%.
Control of rectifier operation, fans, high temp shutoff, voltage or current limits, etc
Local HMI to view data, change set point of reference target, view errors
Logging of data;
Display of data and operator adjustment of reference set point on local HMI
Must be able to connect via phone line or internet (depending on site) to view live data and download datalogs
Linking multiple rectifiers at one site would be ideal; so I would connect to one "master" to download and view all the data
So far, my frontrunner is a Micrologix 1100 ($680 USD) and 2711R-T4T, Panelview 800 display ($407), with a 2 channel AI, 2 channel AO module ($391), and an Advantech ADAM-4019+ universal input card ($361) for the high input AI (20 mOhm) and RTD inputs. I hope this works!
I am unsure what the best method is for phone line access, and datalogging.
I am looking at options from Advantech, Red Lion, and Automation Direct, but they either cost more or have technical constraints.
The operation is as follows:
Analog Inputs: 1-4 x References (-5 to 5V, high input impedence), 1 x shunt to monitor current (0-150mV), 1 x to monitor output voltageDC V (0-12 V can be stepped down if required), 2 x RTD inputs for enclosure/SCR temperature.
Analog Output: PID controlled Process output to SCR trigger module (0-5 or 10 V or 4-20 mA).
Relay/Digital Outputs: to drive fans, status LED, etc.
PID control using reference AI as feedback to drive AO, 0-100%.
Control of rectifier operation, fans, high temp shutoff, voltage or current limits, etc
Local HMI to view data, change set point of reference target, view errors
Logging of data;
Display of data and operator adjustment of reference set point on local HMI
Must be able to connect via phone line or internet (depending on site) to view live data and download datalogs
Linking multiple rectifiers at one site would be ideal; so I would connect to one "master" to download and view all the data
So far, my frontrunner is a Micrologix 1100 ($680 USD) and 2711R-T4T, Panelview 800 display ($407), with a 2 channel AI, 2 channel AO module ($391), and an Advantech ADAM-4019+ universal input card ($361) for the high input AI (20 mOhm) and RTD inputs. I hope this works!
I am unsure what the best method is for phone line access, and datalogging.
I am looking at options from Advantech, Red Lion, and Automation Direct, but they either cost more or have technical constraints.